New data indicates
automakers continue
to innovate with
greater use of
aluminum to boost
fuel economy, cut
emissions and improve
safety. A new study
by Ducker Worldwide,
commissioned by
The Aluminum Association,
Inc., confirms
that in North America
the use of automotive
aluminum is at
an all-time high,
averaging 8.6 percent
of vehicle curb
weight in 2009
calendar year vehicles,
up from just 2
percent in 1970
and 5.1 percent
in 1990. Additionally,
the integration
of aluminum in
cars and light
trucks is projected
to be nearly 11
percent of curb
weight by 2020.

On a worldwide
basis, the amount
of aluminum content
for light vehicles
is 7.8 percent
of the average
worldwide light
vehicle curb weight
of 3,185 lbs. in
2009. Content growth
is predicted to
continue at a rate
of 4 to 5 lbs.
per vehicle, per
year, and approach
300 lbs. per vehicle
worldwide in 2020.

North America continues
to lead

North America ranks
as the world leader
in aluminum penetration
in cars, pickups,
SUVs and minivans
where a net increase
of more than 8
lbs. occurred between
2006 and 2009 calendar
year vehicles despite
a 10 percent loss
in share for large,
full-frame vehicles
with high aluminum
content. More than
50 vehicles produced
in North America
contain over 10
percent aluminum
content.

Honda and BMW are
now the aluminum
content leaders
replacing General
Motors and Nissan
with both companies
averaging more
than 340 lbs. of
aluminum per vehicle.
General Motors,
Honda, Toyota,
BMW, Hyundai and
Volkswagen all
increased the amount
of aluminum content
of their North
American vehicles
from 2006 to 2009.

On a component
basis, the study
cites engine blocks
and steering knuckles
with the ­largest
increase in growth
over the last three
years; with penetration
of aluminum blocks
reaching nearly
70 percent – the
largest driver
of aluminum growth
in this decade.
In addition, more
than 22 percent
of vehicles currently
made in the United
States have aluminum
hoods, an all-time
record.

Global growth continues

Since the 2006
model year, aluminum
content has also
experienced steady
growth in light
vehicle applications
in other regions
of the world, but
especially in Europe
and Japan. Long-term
growth rates remain
in line with the
significant growth
rates of the late
1970s to early
1990s, despite
the shift to smaller
vehicles.

Worldwide aluminum
content is projected
to grow to 28 to
30 billion lbs.
per year – up from
the current 16
to 17 billion pounds
– between now and
2020, not taking
scrap and spare
parts into account.

An estimated total
of 67 vehicles
from the European
(49) and Japanese
(18) markets now
contain more than
400 lbs. of finished
aluminum.

Experts Weigh In

As the future of
the global automotive
industry quickly
shifts to more
fuel-efficient
products, vehicles
around the world
will be manufactured
with a variety
of solutions and
powertrain improvements.
In fact, material
experts and body
engineers surveyed
in this study expect
25 percent of fuel
economy improvement
to come from weight
savings, while
powertrain experts
predict that 50
percent of the
improvements will
be from weight
reduction.

For North America
specifically, the
use of aluminum
as a replacement
for heavier materials
is a very significant
option to improve
fuel economy and
nearly as important
as hybrid technology.